
COURSE CONTENT ON PETHA PROCESSING AATMANIRBHAR BHARAT National Institute of Food Technology Entrepreneurship and Management ` TABLE OF CONTENTS 1. Introduction Page No. 1.1 Indian sweets 3 1.2 Ash Gourd 3-4 1.3. Major component of Ash gourd 4 1.4. Market Potential 5 1.5 Value Added Products From Ash Gourd 5 2. Processing of Petha 2.1. Raw material 6 2.2. manufacturing Process 6 2.3. Processing Technology of Petha 7-10 2.4. Equipments involved 11-12 3. Packaging of Petha 3.1 The factors that lead to spoilage/defects 13 3.2 Selection of Packaging Material 13-15 3.3 Frequently Used Plastic Based Packaging Materials 15-18 3.4 Methods For Petha Packaging 18-20 4. Project component 4.1. Land 21 4.2.Civil work 21 4.3. Power requirement 21 4.4. Manpower requirement 21 5. Food Safety Regulations & Standards 5.1 Food Standards 22-23 5.2 Food Safety 24-25 5.3 Labeling Standards 26 5.4. Application 27 Petha Processing Unit 2 ` CHAPTER 1 INTRODUCTION 1.1. Indian sweets Sweets have been traced to be originated at 500 BCE in the Indian subcontinent that suggests the production of both raw sugar (gur, vellam, jaggery) and refined sugar (sarkara). Five kinds of sugar in the official documents were acknowledged by the kingdom officials in India back at 300 BCE. By the Gupta dynasty era (300–500 CE), sugar was being made not only from sugar cane, but from other plant sources such as palm. Sushruta Samhita records about sugar being produced from mahua flowers, barley (yavasa) and honey and Sugar-based foods were also used in temple offerings as bhoga for the deities which, after the prayers, became prasād for devotees, the poor, or visitors to the temple. It is considered the purest dessert in the world, due to its ingredients, comprising of fruit, sugar and water. Petha is not cooked on a regular cooking fire, but only coal fire was used to prepare this sweet treat. Petha made in Agra has a Geographical Indication (GI) tag to certify its place of origin. With the passage of time, many varieties of Petha have come up in the market to cater to the demand and changing palate of the patrons. Nowadays, buyers can choose from the kesar petha (saffron), angoori petha (grapes), chocolate petha, paan petha, and so on. Coconut and dried fruit lovers can also have their share of the delicious Petha. 1.2. Ash Gourd Ash Gourd is used in the preparation of a dessert called petha, which is the most famous sweet of Agra, the place that also symbolized by Taj Mahal. Ash gourd is very important in Indian religious ceremonies. It is frequently found hanging from a rope in front of newly built houses, as it is believed to ward off evil spirits. This gourd is also ground to a coarse paste and made into Petha Processing Unit 3 ` vadiyaalu (similar to Papad). The gourd stays well for up to three to four months without any special storage facilities. 1.3. Major component of Ash Gourd Principle Nutrient Value Percentage of RDA Energy 13 Kcal 1% Carbohydrates 3g 2.3% Protein 0.4 g <1% Total Fat 0.2 g 1% Cholesterol 0 mg 0% Dietary Fiber 2.9 g 7.6% Vitamins Folates 5 μg 1.25% Niacin 0.400 mg 2.5% Pantothenic acid 0.133 mg 2.5% Pyridoxine 0.035 mg 3% Riboflavin 0.11 mg 1% Thiamin 0.04 mg 3.3% Vitamin-A 0 IU 0% Vitamin-C 13 mg 14% Electrolytes Sodium 6 mg <0.5% Potassium 111 mg 2.4% Minerals Calcium 19 mg 2% Iron 0.4 mg 5% Magnesium 10 mg 2.5% Manganese 0.058 mg 2.5% Phosphorus 19 mg 2.5% Selenium 0.2 μg <1% Petha Processing Unit 4 ` Zinc 0.61 mg 6% 1.4. Market Potential Agra's famous petha sweet industries as well as tourist guides, who went into near closure, are ecstatic. As the Taj Mahal re-opens, the petha industry has greatly benefited. Around 50 % of sales of Petha are due to agro-tourism. However, Petha seems to be just a processed sweet dish, but in Agra and other regions of the areas, it is the lifeline of economy. The sellers, the processor, the distributor are all directly or indirectly linked to Petha processing business and development. About 1500 cottage units produce 700-800 tons of Petha daily. As a result of its strong demand from tourists overseas, Petha also has strong export prospects. In today’s world where businesses face a double challenges of tough competition and the short attention span of the consumer innovation is the only way to survive and thrive. Traditional sweet makers, famous for its translucent, soft candy, petha, have realized this, and are thus innovating the humble sweet in myriad ways. Presently 15 varieties of petha are manufactured in India. There is chocolate, paan, angoori, khus, orange, pineapple, coconut, dry fruits, and Kesar, among others. There is even a sandwich variety which is basically two layers of petha with a filling of khoya, cashew, and cardamom. 1.5. Value Added Product of Ash gourd Ash gourd is an important, under-exploited vegetable that is immensely used in ayurvedic medicine preparations. It has a long storage life and good scope for value addition. The popular value added product of Ash Gourd is: Petha (Candy) Badi (Nugget) Petha Processing Unit 5 ` CHAPTER 2 PROCESSING OF PETHA 2.1. Raw materials (100 Kg) Raw Materials Required Weight 200 250 kg Ash gourd Water 500 liters (As required) 10 Kg Lime Alum 500 g Citric acid 200 g 2.2. Manufacturing Process Petha Fruits (Ash Gourd) are directly procured from the farmer’s field. Washing, Sorting, and peeling of Petha fruit is done manually. Then they are cut into pieces. The seed of the fruit is removed from the fruit by an SS knife Cutting them into small pieces. These pieces are pierced with nail-like spikes. Pierced pieces are then immersed in Lime Water for 2 hrs. Then these pieces are boiled in water with Alum. After they are boiled, the Pieces are finally immersed in boiling sugar syrup for an hour. Finally, these pethas are dried in trays for further packaging. Final packaging is done and sends to the market. Petha Processing Unit 6 ` 2.3. Processing technology of Petha Fruit selection and harvesting of Ash Gourd The fruits are directly procured from farmer field; the ash gourd to be candied must be of perfect maturity stage and is free of fibers. Peeling, Cutting & Seed Removal The harvested wax gourd is washed and cleaned. The seeds are removed and It is then peeled and cut at an approximate dimension (cubical, cylindrical or spherical.), dimension and shape can vary according to choice. Piercing or Forking After peeling and cutting operations, pieces of Ash Gourd are pierced with metal to ensure proper porosity. This would at last ensure proper entry of the sugar syrup. Soaking in lime water The pierced/forked pieces of Petha are then dipped in lime water for around 2-3 hours. The proportion used is usually 20 kilograms of lime per 100 liters of water. This process helps to harden Petha to makes it compact. The methodology behind the use of calcium in the fruit slices to create an intercellular bond and making it more textured and rigid. Washing in running water After Dipping Petha in lime water, it is washed constantly in clear running water to wash the calcium dipped bits in running water until the lime is completely washed away. In order to ensure the elimination of excess calcium ions, this is an essential and mandatory process. Dipping in chilled water The petha is dipped in chilled water after being cleaned in running water to reduce exothermic reactions due to excess Ca2+ ions are minimized. This is done for half an hour or 1 hour. Hot water treatment Now the fruits pieces are dip in hot water (80-900C), to minimize the characteristic taste of gourds. This is done within 5-10 minutes. Petha Processing Unit 7 ` Boiling with Alum Petha bits are boiled for one hour in water containing alum. This process is called, ‘Josh Lena’. In order to preserve the standard of Petha, this is a very important step that must be performed cautiously and skillfully. This is achieved to maintain surface smoothness and reduce the effects of exothermic damage caused by excess calcium ions in the fruit tissues. Preparation of sugar syrup 70-80% of sugar is dissolved in water and is boiled at 1000C. After cooking for 5-10 minutes citric acid 2-3g is added / liter of water. Boiling with sugar syrup The treated fruit pieces are dipped in boiling sugar syrup of suitable consistency. The sugar syrup and the fruit parts are boiled until the sugar syrup reaches a very high consistency (up to 80- 90 percent). To ensure consistent mixing, the petha is cooked properly and stirred periodically. After cooking properly Petha are covered with mesh overnight so that a sufficient amount of sugar enters into the innermost part of the fruit pieces. Draining of excess sugar The excess syrup is drained out. Then one then Rose petals, essence & flavoring agents such as saffron, are added to make different flavors of pethas. It is then cooled into assorted boxes and bins until it is packaged. Cooling and packing After overnight soaking, the Petha are cooled and are packed airtight. Petha Processing Unit 8 ` Petha Processing Unit 9 ` Flow chart of Petha preparation Mature Ash gourd fruit sleeted Washing in tap water Cutting horizontally with sharp stainless steel knife Removal of peel Immediate pricking with stainless fork Dipping of ash gourd pieces in lime water with occasional stirring for 2 -3 hours Washing with running water for 5-10 min Dipping in chilled water (5-7oC) for 1 hours Cooking of ash gourd in boiling water (100oC for 5 min) Hot water (60-70oC) dipping for 5-10 mnt for removal of vegetable flavour Boiling with Alum Sugar syrup (70-80 % sugar) preparation with citric acid Cooking of ash gourd in sugar syrup up to 68-70o Brix Covered with mesh overnight Draining of excess sugar Cooling and packing polypropylene pouches o Petha Processing Unit Storage at ambient temperature (15- 20 C) 10 ` 2.4.
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